KTM 250, 300, 380, 400, 520, 525, 540, 560, 610 Repair Service Manual 1983-2010
Complete service repair manual with Electrical Wiring Diagrams for 1983-2010 KTM 250, 300, 380, 400, 520, 525, 540, 560, 610, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
KTM 250, 300, 380, 400, 520, 525, 540, 560, 610 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
MAKE: KTM
YEAR: 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010
MODEL: 250 EGS, 250 EXC, 250 EXC, 250 EXC-F (AUS/EU/USA), 250 EXC-F SIX DAYS, 250 EXC SIX DAYS, 250 EXC-USA, 250GS, 250 MX, 250 MXC, 250 SX, 250 SX-F, 250 SXS, 250 SXS-F, 250 XC, 250 XC-F, 250 XCF-W, 250 XC-W, 300 EGS, 300 EXC, 300 EXC SIX DAYS, 300 EXC-USA, 300 MXC, 300SX, 300 SXS, 300 XC, 300 XC-W, 380 EGS, 380 SX, 380 MXC, 380 EXC, 400 SX, 400 MXC, 400 XC, 400 EXC, 400 SMR, 400 SXS RACING, 450 SX, 400 MXC, 400 XC, 400 EXC, 400 SMR, 400 SXS RACING, 520 SX, 520 MXC, 520 XC, 520 EXC, 520 SMR RACING, 525 SX, 525 MXC, 525 XC, 525 EXC, 525 SMR RACING, 540 SXS, 560 SMR, 610 CRATE
"'04-'10 250-300.pdf"
229 pages; 2004-2007 Repair Manual for 250 EXC, 250 EXC, 250 EXC SIX DAYS, 250 EXC-USA, 250 MXC, 250 SX, 250 SXS, 250 XC, 250 XC-W, 300 EXC, 300 EXC SIX DAYS, 300 EXC-USA, 300 MXC, 300SX, 300 XC, 300 XC-W
"'05-'10 250"
55 MB, 700+ pages PDF; 2005-2010 Service Manual for 250 EXC-F (AUS/EU/USA), 250 EXC-F SIX DAYS, 250 SX-F, 250 SXS-F, 250 XC-F, 250 XCF-W
"'05-'08 250"
177 MB, 3,000+ pages PDF, EN/DE/FR/IT/ES; 2005-2008 Service Manual (Repair Manual. Owner's Manual...) for 250 SX-F, 250 EXC-F (USA/EU), 250 EXC-F SIX DAYS, 250 XCF-W, 250 XC-F, 250 SXS-F
"'00-'06 250-610"
35 MB, 600+ PDF, 2000-2006 Service Manual (Repair Manual. Owner's Manual...) for 250 EXC RACING
400 SX, 400 MXC, 400 XC, 400 EXC, 400 SMR, 400 SXS RACING, 450 SX, 400 MXC, 400 XC, 400 EXC, 400 SMR, 400 SXS RACING, 520 SX, 520 MXC, 520 XC, 520 EXC, 520 SMR RACING, 525 SX, 525 MXC, 525 XC, 525 EXC, 525 SMR RACING, 540 SXS, 560 SMR, 610 CRATE
"'04-'06 250-300.pdf"
159 pages; Repair Manual 2004-2006 for 250 SX, 250 SXS, 250 MXC, 250 EXC, 250 EXC SIX DAYS, 250 XC, 250 XC-W, 300 SX, 300 SXS, 300 MXC, 300 EXC, 300 EXC SIX DAYS, 300 XC, 300 XC-W
"'05-'06 250 SX-F.pdf"
125 pages; Repair Manual for 2005-2006 250 SX-F
"'99-'03 250-300-380 SX, MXC, EXC.pdf"
153 pages; Repair Manual 1999-2003 for 250 EGS, 250 SX, 250 MXC, 250 EXC, 300 EGS, 300 SX, 300 MXC, 300 EXC, 380 EGS, 380 SX, 380 MXC, 380 EXC
"'00-'03 250-525 SX_MXC_EXC Racing.pdf"
167 pages; Repair Manual Engine for 250-400-520-525 SX, MXC, EXC RACING
"250MX ('83-'91), 250MXC ('84-'03), 250GS ('83-'99) (EN-DE).pdf"
63 pages, EN/DE; 250MX ('83-'91), 250MXC ('84-'03), 250GS ('83-'99) Owners Repair Manual
PRODUCT DETAILS:
Total Pages: 613 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
KTM 200-300 Series Repair Manual 2004-2010...2
HOME...0
NOTES AND PREFACE...0
Important information...4
Updating instructions...4
Explanation updating...6
Introduction...8
Reply fax for repair manuals...10
TABLE OF CONTENTS...2
GENERAL INFORMATION...12
SPECIAL TOOLS - ENGINE...14
CHECKING THE SETTING OF THE TVC SYSTEM...15
ENGINE CHARACTERISTIC...15
BLEEDING THE HYDRAULIC CLUTCH (UP TO MODEL 2005)...16
BLEEDING THE HYDRAULIC CLUTCH (AS OF MODEL 2006)...17
CHANGING THE FRONT BRAKE FLUID...18
CHANGING THE REAR BRAKE FLUID...19
CHECKING BRAKE PADS AND BRAKE DISCS...19
REMOVING AND REFITTING ENGINE...20
REMOVING THE ENGINE...22
REFITTING THE ENGINE...24
DISASSEMBLING THE ENGINE...28
PREPARATION...30
DRAINING THE GEAR OIL...30
DISMOUNTING THE SPROCKET AND SHIFT LEVER...30
DISMOUNTING THE CYLINDER HEAD, CYLINDER AND PISTON...30
DISMOUNTING THE CLUTCH COVER...31
DISMOUNTING THE PRESSURE CAP AND THE CLUTCH DISCS...32
DISMOUNTING THE PRIMARY DRIVE...32
DISMOUNTING THE KICKSTARTER SHAFT...33
DISMOUNTING THE SHIFT LOCK...33
DISMOUNTING THE IGNITION COVER...33
DISMOUNTING THE IGNITION...34
DISMOUNTING THE REED VALVE HOUSING...35
PARTING THE ENGINE HOUSING HALVES...35
DISMOUNTING THE GEARSHIFT MECHANISM AND TRANSMISSION...35
DISMOUNTING THE CRANKSHAFT...36
SERVICING INDIVIDUAL COMPONENTS...38
SERVICING THE RIGHT ENGINE HOUSING HALF...40
SERVICING THE LEFT ENGINE HOUSING HALF...41
CRANKSHAFT...42
CRANKSHAFT WEBS - MEASURE OUTER DIMENSION...42
CHECK THE PISTON...42
PISTON RING END GAP...42
MEASURING PISTONS AND CYLINDERS - ESTABLISHING THE PISTON MOUNTING CLEARANCE...43
RECOATED CYLINDER...43
NIKASIL COATING OF CYLINDER...43
CYLINDER EXHAUST CONTROL SYSTEM...44
CYLINDER PREASSEMBLY...44
EXHAUST CONTROL, CLUTCH COVER...46
PREASSEMBLY OF CLUTCH COVER...46
REED VALVE HOUSING...47
CLUTCH...48
REPLACE OUTER CLUTCH HUB...49
SHIFT MECHANISM...50
PREASSEMBLY THE SHIFT SHAFT...50
ASSEMBLY MAINSHAFT...51
ASSEMBLY COUNTERSHAFT...52
CHECKING THE KICKSTARTER FOR WEAR...53
ASSEMBLING THE KICKSTARTER SHAFT...53
CHECKING THE ELECTRIC STARTER MOTOR FOR WEAR...54
ELECTRIC STARTER MOTOR - CHECKING FOR AND ADJUSTING PLAY...54
ASSEMBLING THE ENGINE...56
CRANKSHAFT...58
TRANSMISSION...58
ASSEMBLING THE ENGINE HOUSING...59
MOUNTING THE SHIFT MECHANISM...60
MOUNTING THE KICKSTARTER SHAFT...60
MOUNTING THE PRIMARY DRIVE AND CLUTCH...61
MOUNTING THE CLUTCH DISCS AND PRESSURE CAP...62
MOUNTING THE CLUTCH COVER...62
MOUNTING THE PISTON AND CYLINDER...63
ADJUSTING DIMENSION “X“...63
ADJUSTING THE CONTROL FLAP (DIMENSION “Z“)...64
MOUNTING THE STEERING COVERS...65
MOUNTING THE CYLINDER HEAD...65
MOUNTING THE REED VALVE HOUSING...65
MOUNTING THE ENGINE SPROCKET...66
MOUNTING THE IGNITION (WITHOUT ELECTRIC STARTER)...66
MOUNTING THE IGNITION COVER (WITHOUT ELECTRIC STARTER)...67
MOUNTING THE IGNITION (WITH ELECTRIC STARTER)...67
MOUNTING THE IGNITION COVER (WITH ELECTRIC STARTER)...67
MOUNTING THE OUTER IGNITION COVER (WITH ELECTRIC STARTER)...67
MOUNTING THE ELECTRIC STARTER...67
FIXING THE STARTER DRIVE COVER (WITH ELECTRIC STARTER)...67
FITTING THE PUSH ROD...68
MOUNTING THE STARTING LEVER AND SHIFT LEVER...68
FILLING UP THE TRANSMISSION OIL...68
CHECK THE TRANSMISSION OIL LEVEL...68
ELECTRICAL...70
IGNITION COIL...72
CDI UNIT...72
CHECKING THE VOLTAGE REGULATOR...72
CHECKING THE CAPACITOR...73
SPARK PLUG...73
IGNITION...73
CHECK THE STATOR AND PULSE GENERATOR (PICK UP)...74
MEASUREMENTS WITH PEAK VOLTAGE ADAPTER...70
MODEL 2004...70
STATIC IGNITION VALUES 250 SX, 250/300 MXC/EXC...75
STATIC GENERATOR VALUES 250/300 MXC/EXC...77
STATIC IGNITION AND GENERATOR VALUES 250 EXC USA...79
MODEL 2005...70
STATIC IGNITION VALUES 250 SX, 250/300 MXC/EXC...81
STATIC GENERATOR VALUES 250/300 MXC/EXC...83
STATIC IGNITION AND GENERATOR VALUES 250 EXC USA...85
MODEL 2006...70
STATIC IGNITION VALUES 250 SX/SXS, 250/300 EXC/EXC SIX DAYS, 300 XC/XC-W...81
STATIC GENERATOR VALUES 250/300 EXC/EXC SIX DAYS, 300 XC-W...83
STATIC IGNITION AND GENERATOR VALUES 250 XC/XC-W...85
MODEL 2007-...70
STATIC IGNITION VALUES 250/300 EXC-E FROM 2007...87
STATIC GENERATOR VALUES 250/300 EXC-E FROM 2007...89
DYNAMIC GENERATOR VALUES 250/300 EXC-E FROM 2007...91
FUEL SYSTEM...92
OPERATING RANGES OF THE CARBURETOR...94
CARBURETOR ADJUSTMENT...95
DISMOUNTING AND INSTALLING THE CARBURETOR...97
DISASSEMBLING THE CARBURETOR...98
CHECKING THE JET NEEDLE AND THROTTLE SLIDE...99
CHECKING THE STARTING PISTON...99
CHECKING THE FLOAT NEEDLE VALVE...99
CHECKING THE CARBURETOR JETS AND GASKETS...99
ASSEMBLING THE CARBURETOR...100
DRAINING THE CARBURETOR FLOAT CHAMBER...101
CHECKING THE FLOAT LEVEL...101
TROUBLE SHOOTING...102
TROUBLE SHOOTING 250 / 300...104
TECHNICAL SPECIFICATIONS...106
MODEL 2004...106
ENGINE...110
CHASSIS...111
MODEL 2005...106
ENGINE...112
CHASSIS...113
MODEL 2006...106
ENGINE 250...114
ENGINE 300...115
CHASSIS SX / SXS / EXC / EXC SIX DAYS...116
CHASSIS XC / XC-W...117
MODEL 2007...106
ENGINE 250 SX...118
ENGINE 250/300 XC / XC-W / EXC / EXC SIX DAYS...120
CHASSIS 250 SX...119
CHASSIS 250/300 XC / XC-W / EXC / EXC SIX DAYS...121
MODEL 2008...106
ENGINE 250 SX...123
ENGINE 250 XC / XC-W / EXC / EXC SIX DAYS...124
ENGINE 300 XC / XC-W / EXC / EXC SIX DAYS...125
CHASSIS 250 SX...126
CHASSIS 250/300 XC / XC-W / EXC / EXC SIX DAYS...127
MODEL 2009...106
ENGINE 250 SX...129
ENGINE 250 XC / XC-W / EXC / EXC SIX DAYS...130
ENGINE 300 XC / XC-W / EXC / EXC SIX DAYS...131
CHASSIS 250 SX...132
CHASSIS 250/300 XC / XC-W / EXC / EXC SIX DAYS...133
MODEL 2010...108
ENGINE 250 SX...135
ENGINE 250 XC / XC-W / EXC / EXC SIX DAYS...136
ENGINE 300 XC / XC-W / EXC / EXC SIX DAYS...137
CHASSIS 250 SX...138
CHASSIS 250/300 XC / XC-W / EXC / EXC SIX DAYS...139
TIGHTENING TORQUES - ENGINE...141
TOLERANCES AND FITTING CLEARANCES / GASKET THICKNESSES...141
TIGHTENING TORQUES - CHASSIS...142
CARBURATOR SPECIFICATION...106
MODEL 2004...143
MODEL 2005...145
MODEL 2006...147
MODEL 2007...150
MODEL 2008...153
MODEL 2009...157
MODEL 2010...157
PERIODIC MAINTENANCE SCHEDULE...162
MODEL 2004 / 2005...164
MODEL 2006...167
MODEL 2007...169
MODEL 2008...173
MODEL 2009...173
MODEL 2010...177
WIRING DIAGRAM...182
MODEL 2004...186
MODEL 2005...193
MODEL 2006...194
MODEL 2007...212
MODEL 2008/2009...216
MODEL 2010...223
KTM 250 SX-F Repair Manual 2005-2006...231
HOME...0
NOTES AND PREFACE...231
Title page and file spine...231
Explanation update...237
Introduction...239
Reply fax for repair manuals...241
TABLE OF CONTENTS...235
SERVICE-INFORMATIONS...231
GENERAL INFORMATION...243
BLEEDING THE COOLING SYSTEM...245
CHANGING THE OIL FILTER...245
OIL CIRCUIT...246
BLEEDING OF THE HYDRAULIC CLUTCH...247
ADJUSTING THE THROTTLE CABLES...247
SPECIAL TOOLS ENGINE...248
REMOVING AND REFITTING ENGINE...251
DISMOUNTING THE ENGINE...253
MOUNTING THE ENGINE...257
DISASSEMBLING THE ENGINE...261
PREPARATORY WORK...263
MOVING THE ENGINE INTO THE TDC POSITION...264
REMOVING THE CAMSHAFTS...265
REMOVING THE CYLINDER HEAD AND PISTON...266
REMOVING THE CLUTCH COVER...268
DISMANTLING THE CLUTCH...269
REMOVING THE CHAIN DRIVE AND PRIMARY GEAR...270
DISMANTLING THE SHIFT MECHANISM...271
REMOVING THE OIL PUMPS...272
SEPARATING THE CASING HALVES, REMOVING THE CRANKSHAFT AND TRANSMISSION SHAFTS...273
SERVICING INDIVIDUAL COMPONENTS...275
LEFT CASING HALF...277
RIGHT CASING HALF...278
BYPASS VALVE...279
CLUTCH COVER...279
CRANKSHAFT...280
MEASURING THE OUTSIDE DIMENSION OF THE CRANKSHAFT WEBS...281
CRANKSHAFT BEARINGS...281
AXIAL CLEARANCE OF THE CRANKSHAFT...281
CYLINDER...282
MEASURING THE PISTON AND CYLINDER, MOUNTING CLEARANCE...282
PISTON...283
PISTON RING END GAP...283
CHECKING THE OIL PUMPS FOR WEAR...283
LUBRICATING SYSTEM...284
CAMSHAFT BEARING...285
CAMSHAFTS...286
AUTOMATIC DECOMPRESSION...286
CAMSHAFT BEARING BRIDGES...287
TIMING CHAIN TENSIONER...288
TIMING TRAIN...289
CYLINDER HEAD...290
CLUTCH...292
KICKSTARTER...293
PRE-MOUNTING THE KICKSTARTER SHAFT...293
SHIFT MECHANISM...295
PRE-MOUNTING THE SHIFT SHAFT...295
GENERAL INFORMATION ON SERVICING THE TRANSMISSION...296
ASSEMBLING THE MAIN SHAFT...296
ASSEMBLING THE COUNTERSHAFT...297
ASSEMBLING THE ENGINE...299
INSTALLING THE TRANSMISSION SHAFTS AND CRANKSHAFT, ASSEMBLING THE CASING HALVES...301
MOUNTING THE OIL PUMPS...303
MOUNTING THE SHIFT MECHANISM...305
MOUNTING THE PRIMARY PINION AND THE CHAIN DRIVE...306
MOUNTING THE CLUTCH...307
MOUNTING THE CLUTCH COVER...308
MOUNTING THE PISTON AND CYLINDER HEAD...309
MOUNTING THE CAMSHAFTS...312
MOUNTING THE CHAIN TENSIONER...313
CHECKING THE VALVE CLEARANCE...313
ASSEMBLING THE ENGINE...314
ELECTRICAL...315
CDI UNIT...317
CHECKING THE IGNITION COIL...317
TROUBLESHOOTING IN THE IGNITION SYSTEM...317
IGNITION SYSTEM...318
CHECKING THE STATOR AND PULSE GENERATOR...318
REPLACING THE STATOR...318
MEASURING WITH THE PEAK VOLTAGE ADAPTER...319
THROTTLE VALVE SENSOR...315
ADJUSTING...332
CHECKING...333
FUEL SYSTEM...321
DISMOUNTING AND INSTALLING THE CARBURETOR...324
DISASSEMBLING THE CARBURETOR...325
CHOKE KNOB AND HOT START SLIDE...328
CHECKING THE ACCELERATOR PUMP...328
CHECKING THE JET NEEDLE...328
CHECKING THE FLOAT NEEDLE VALVE...328
CHECKING THE THROTTLE VALVE...328
ASSEMBLING THE CARBURETOR...329
ADJUSTING THE POSITION OF THE THROTTLE VALVE SENSOR...332
CHECKING THE THROTTLE VALVE SENSOR...333
DISMOUNTING AND INSTALLING THE THROTTLE VALVE SENSOR...333
CARBURETOR ADJUSTING IDLING...334
CHECKING/ADJUSTING THE FLOAT HEIGHT...335
TROUBLE SHOOTING...337
TECHNICAL SPECIFICATIONS...341
ENGINE...343
CHASSIS...344
MOUNTING CLEARANCES, WEAR LIMITS...345
TIGHTENING TORQUES...341
ENGINE...346
CHASSIS...347
PERIODIC MAINTENANCE SCHEDULE...349
250 SX-F...350
WIRING DIAGRAMS...353
WIRING DIAGRAM...354
CABLE COLORS...355
KTM 250 Series Repair Manual 2005-2008 (EN-DE-FR-ES-IT)...356
sprachauswahl...357
KTM 250 Series Repair Manual 2005-2010...358
09_3211348_en_OM...359
MEANS OF REPRESENTATION...365
IMPORTANT NOTES...366
VIEW OF VEHICLE...368
View of the vehicle from the left front (example)...368
View of the vehicle from the right rear (example)...369
LOCATION OF SERIAL NUMBERS...370
Chassis number...370
Type label...370
Key number (EXC-F, EXC‑F SIX DAYS)...370
Engine number...370
Fork part number...370
Shock absorber part number...371
CONTROLS...372
Clutch lever...372
Hand brake lever...372
Short circuit button (XCF‑W, XC‑F, SX‑F)...372
Short circuit button (EXC-F, EXC‑F SIX DAYS)...372
Emergency OFF switch (250 EXC-F AUS)...372
Electric starter button (EXC‑F EU, EXC‑F SIX DAYS, XCF‑W, XC‑F)...373
Electric starter button (250 EXC-F AUS)...373
Light switch (EXC-F, EXC‑F SIX DAYS)...373
Light switch (XCF‑W)...373
Horn button (EXC-F, EXC‑F SIX DAYS)...373
Flasher switch (EXC-F, EXC‑F SIX DAYS)...374
Overview of indicator lamps (EXC-F, EXC‑F SIX DAYS)...374
CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W)...375
Speedometer...375
Speedometer activation and test...375
Tripmaster switch...375
Setting kilometers or miles...375
Setting the clock...376
Adjusting the speedometer functions...376
Querying the lap time...377
SPEED display mode (speed)...377
SPEED/H display mode (service hours)...377
SPEED/CLK display mode (time)...378
SPEED/LAP display mode (lap time)...378
SPEED/ODO display mode (odometer)...378
SPEED/TR1 display mode (trip master 1)...378
SPEED/TR2 display mode (trip master 2)...379
SPEED/A1 display mode (average speed 1)...379
SPEED/A2 display mode (average speed 2)...379
SPEED/S1 display mode (stop watch 1)...380
SPEED/S2 display mode (stop watch 2)...380
CONTROLS...382
Fuel tap (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)...382
Fuel tap (SX‑F)...382
Opening filler cap...382
Closing filler cap...383
Choke (EXC-F EU, EXC‑F SIX DAYS)...383
Choke (EXC‑F AUS, XCF‑W, XC‑F, SX‑F)...383
Shift lever...383
Foot brake pedal...384
Kickstarter...384
Side stand (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)...384
Plug-in stand (SX‑F)...384
Steering lock (EXC-F, EXC‑F SIX DAYS)...385
Locking the steering (EXC-F, EXC‑F SIX DAYS)...385
Unlocking the steering (EXC-F, EXC‑F SIX DAYS)...385
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION...386
Advice on first use...386
Running in the engine...387
RIDING INSTRUCTIONS...388
Checks before putting into operation...388
Starting...388
Starting up...389
Shifting, riding...389
Braking...389
Stopping, parking...390
Refueling...390
SERVICE SCHEDULE (EXC‑F, EXC‑F SIX DAYS, XCF-W)...392
Important maintenance work to be carried out by an authorized KTM workshop...392
Important maintenance work to be carried out by an authorized KTM workshop (as additional order)...393
SERVICE SCHEDULE (XC‑F, SX‑F)...394
Important maintenance work to be carried out by an authorized KTM workshop...394
Important maintenance work to be carried out by an authorized KTM workshop (as additional order)...395
SERVICE SCHEDULE FOR RIDER...396
Important checks and maintenance work to be carried out by the rider...396
MAINTENANCE WORK ON CHASSIS AND ENGINE...397
Jacking up the motorcycle...397
Removing the motorcycle from the work stand...397
Checking the basic chassis setting with the rider's weight...397
Compression damping of shock absorber...397
Adjusting high-speed compression damping of the shock absorber...397
Adjusting the low-speed compression damping of the shock absorber...398
Adjusting the rebound damping of the shock absorber...399
Measuring rear wheel sag unloaded...400
Checking the static sag of the shock absorber...400
Checking the riding sag of the shock absorber...401
Adjusting the spring preload of the shock absorber x...401
Adjusting the riding sag x...402
Removing the shock absorber x...402
Installing the shock absorber x...402
Checking basic setting of fork...403
Adjusting the compression damping of the fork...403
Adjusting the rebound damping of fork...404
Adjusting the spring preload of the fork (EXC‑F, EXC‑F SIX DAYS, XCF-W)...405
Bleeding fork legs...405
Cleaning dust boots of fork legs...406
Loosening the fork protection...406
Positioning the fork protection...406
Checking play of steering head bearing...406
Adjusting play of steering head bearing x (EXC‑F EU, EXC‑F AUS, XCF‑W ZA)...407
Adjusting play of steering head bearing x (EXC‑F SIX DAYS, XCF‑W USA, XC‑F, SX‑F)...407
Fork offset (XCF‑W USA, XC‑F, SX‑F)...408
Setting the fork offset x (XCF‑W USA, XC‑F, SX‑F)...408
Removing the fork legs...408
Installing the fork legs x...409
Removing the fork protector x...410
Installing the fork protector x...410
Removing the lower triple clamp x (EXC‑F SIX DAYS, XCF‑W USA, XC‑F, SX‑F)...410
Removing the lower triple clamp x (EXC‑F EU, EXC‑F AUS, XCF‑W ZA)...411
Installing the lower triple clamp x (EXC‑F SIX DAYS, XCF‑W USA, XC‑F, SX‑F)...411
Installing the lower triple clamp x (EXC‑F EU, EXC‑F AUS, XCF‑W ZA)...412
Greasing the steering head bearing x...413
Dismounting the front fender...413
Installing the front fender...413
Removing headlight mask with headlight (EXC‑F, EXC‑F SIX DAYS, XCF-W ZA)...413
Refitting the headlight mask with the headlight (EXC‑F, EXC‑F SIX DAYS, XCF-W ZA)...414
Dismount the start number plate (XCF‑W USA, XC‑F, SX‑F)...414
Installing the start number plate (XCF‑W USA, XC‑F, SX‑F)...414
Handlebar position...414
Adjusting the handlebar position x...415
Checking gas Bowden cable route...416
Checking play in the gas Bowden cable...416
Adjusting the gas Bowden cable play x...417
Checking for chain dirt accumulation...417
Cleaning the chain...417
Checking the chain tension...418
Checking the chain tension when fitting rear wheel...418
Checking the rear sprocket / engine sprocket for wear...419
Checking chain wear...419
Adjusting the chain tension...419
Adjusting chain tension - after checking...420
Adjusting chain tension - fitting rear wheel...421
Adjusting the chain guide x (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)...421
Adjusting the chain guide x (SX‑F)...422
Adjusting basic position of clutch lever...422
Checking the fluid level of hydraulic clutch...422
Changing the hydraulic clutch fluid x...423
Checking the brake discs...424
Checking free travel of hand brake lever...424
Adjusting basic position of handbrake lever (XCF‑W, XC‑F, SX‑F)...424
Adjusting free travel of handbrake lever (EXC-F, EXC‑F SIX DAYS)...425
Checking the front brake fluid level...425
Adding front brake fluid x...425
Checking the front brake linings...426
Removing the front brake linings x...426
Installing the front brake linings x...427
Changing the front brake linings x...427
Checking free travel of foot brake lever...428
Adjusting basic position of footbrake lever x...428
Checking the rear brake fluid level...429
Adding brake fluid for the rear brake x...429
Checking the rear brake linings...430
Removing rear brake linings x...430
Installing the rear brake linings x...430
Changing the rear brake linings x...431
Removing the front wheel x...432
Installing the front wheel x...432
Removing rear wheel x...433
Installing the rear wheel x...433
Tire condition checking...434
Checking tire air pressure...435
Checking spoke tension...435
Removing the battery x (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)...435
Installing the battery x (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)...436
Recharging the battery x (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)...436
Removing a fuse (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)...437
Replacing the fuse (EXC‑F, EXC‑F SIX DAYS, XCF‑W, XC‑F)...437
Removing the seat...437
Mounting the seat...438
Dismounting the fuel tank x...438
Installing the fuel tank x...439
Cooling system...439
Checking antifreeze and coolant level...440
Checking the coolant level...440
Draining the coolant x...441
Refilling coolant x...441
Glass fiber yarn filling of main silencer...441
Removing main silencer...442
Installing the main silencer...442
Dismounting the air filter box lid...442
Installing the air filter box lid...442
Removing the air filter x...443
Installing the air filter x...443
Cleaning air filter x...443
Carburetor - idle...444
Carburetor - adjusting idle x...444
Emptying the carburetor float chamber x...445
Checking the engine oil level...446
Changing the engine oil and oil filter, cleaning the oil screen x...446
Draining the engine oil x...446
Cleaning the oil screens x...447
Removing the oil filter x...448
Installing the oil filter x...448
Filling up with engine oil x...449
Adding engine oil...449
TROUBLESHOOTING...450
CLEANING...452
Cleaning motorcycle...452
STORAGE...453
Storage...453
Putting into operation after storage...453
TECHNICAL DATA - ENGINE...454
Capacity- engine oil...455
Capacity - coolant...455
TECHNICAL DATA - ENGINE TIGHTENING TORQUES...456
TECHNICAL DATA - CARBURETOR...458
EXC-F, EXC‑F SIX DAYS...458
XCF‑W, 250 XC-F USA...458
SX‑F...458
TECHNICAL DATA - CHASSIS...459
Lighting equipment...460
Tires...460
Capacity - fuel...460
TECHNICAL DATA - FORK...461
EXC‑F, EXC‑F SIX DAYS, XCF-W...461
250 XC-F USA...461
250 SX-F EU...462
250 SX-F USA...462
TECHNICAL DATA - SHOCK ABSORBER...463
EXC‑F, EXC‑F SIX DAYS, XCF-W...463
250 XC-F USA...463
250 SX-F EU...464
250 SX-F USA...464
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES...465
WIRING DIAGRAM...466
Wiring diagram (EXC-F EU, EXC‑F SIX DAYS)...466
Wiring diagram (250 EXC-F AUS)...470
Wiring diagram (XCF‑W, 250 XC-F USA)...472
Wiring diagram (SX‑F)...474
SUBSTANCES...476
AUXILIARY SUBSTANCES...477
STANDARDS...479
INDEX...480
A...480
B...480
C...480
D...480
E...480
F...480
G...481
H...481
K...481
L...481
M...481
O...481
P...481
R...481
S...481
T...482
V...482
W...482
10_3211465en_OM...484
MEANS OF REPRESENTATION...490
IMPORTANT INFORMATION...491
VIEW OF VEHICLE...493
View of the vehicle from the left front (example)...493
View of the vehicle from the right rear (example)...494
LOCATION OF SERIAL NUMBERS...495
Chassis number...495
Type label...495
Key number (EXC-F, EXC‑F SIX DAYS)...495
Engine number...495
Fork part number...495
Shock absorber part number...496
CONTROLS...497
Clutch lever...497
Hand brake lever...497
Short circuit button (XCF‑W, SX‑F)...497
Short circuit button (EXC-F, EXC‑F SIX DAYS)...497
Emergency OFF switch (EXC‑F AUS)...497
Electric starter button (EXC‑F EU, EXC‑F SIX DAYS, XCF‑W)...498
Electric starter button (EXC‑F AUS)...498
Light switch (EXC-F, EXC‑F SIX DAYS)...498
Horn button (EXC-F, EXC‑F SIX DAYS)...498
Turn signal switch (EXC-F, EXC‑F SIX DAYS)...498
Overview of indicator lamps (EXC-F, EXC‑F SIX DAYS)...499
CONTROLS (EXC‑F, EXC‑F SIX DAYS, XCF-W)...500
Speedometer...500
Speedometer activation and test...500
Tripmaster switch...500
Setting kilometers or miles...500
Setting the clock...501
Adjusting the speedometer functions...501
Querying the lap time...502
SPEED display mode (speed)...502
Display mode SPEED/H (service hours)...502
Display mode SPEED/CLK (clock)...503
Display mode SPEED/LAP (lap time)...503
Display mode SPEED/ODO (odometer)...503
Display mode SPEED/TR1 (trip master 1)...503
Display mode SPEED/TR2 (trip master 2)...504
Disply mode SPEED/A1 (average speed 1)...504
Display mode SPEED/A2 (average speed 2)...504
Display mode SPEED/S1 (stop watch 1)...505
Display mode SPEED/S2 (stop watch 2)...505
CONTROLS...507
Fuel tap (EXC‑F, EXC‑F SIX DAYS, XCF-W)...507
Fuel tap (SX‑F)...507
Opening filler cap...507
Closing filler cap...508
Choke (EXC-F EU, EXC‑F SIX DAYS)...508
Choke (XCF‑W, SX‑F, EXC‑F AUS)...508
Shift lever...508
Foot brake lever...509
Kick starter...509
Side stand (EXC‑F, EXC‑F SIX DAYS, XCF-W)...509
Plug-in stand (SX‑F)...509
Steering lock (EXC-F, EXC‑F SIX DAYS)...510
Locking the steering (EXC-F, EXC‑F SIX DAYS)...510
Unlocking the steering (EXC-F, EXC‑F SIX DAYS)...510
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION...511
Advice on first use...511
Running-in the engine...512
Preparing vehicle for arduous riding conditions...512
Preparing for riding on dry sand...512
Preparing for riding on wet sand...513
Preparing for riding on wet and muddy surfaces...514
Preparing for rides at high temperature and slow speed...515
Preparing for rides at low temperatures or in snow...515
RIDING INSTRUCTIONS...516
Checks before putting into operation...516
Starting...516
Starting up...517
Shifting, riding...517
Braking...517
Stopping, parking...518
Refueling...518
SERVICE SCHEDULE (EXC‑F, EXC‑F SIX DAYS, XCF-W)...520
Important maintenance work to be carried out by an authorized KTM workshop...520
Important maintenance work to be carried out by an authorized KTM workshop (as additional order)...521
SERVICE SCHEDULE (SX‑F)...522
Important maintenance work to be carried out by an authorized KTM workshop...522
Important maintenance work to be carried out by an authorized KTM workshop (as additional order)...523
SERVICE SCHEDULE FOR RIDER...524
Important checks and maintenance work to be carried out by the rider...524
MAINTENANCE WORK ON CHASSIS AND ENGINE...525
Jacking up the motorcycle...525
Removing the motorcycle from the work stand...525
Checking the basic suspension setting with the rider's weight...525
Compression damping of shock absorber...525
Adjusting high-speed compression damping of the shock absorber...525
Adjusting the low-speed compression damping of the shock absorber...526
Adjusting the rebound damping of the shock absorber...527
Measuring rear wheel sag unloaded...527
Checking the static sag of the shock absorber...528
Checking the riding sag of the shock absorber...528
Adjusting the spring preload of the shock absorber x...528
Adjusting the riding sag x...529
Removing the shock absorber x...530
Installing the shock absorber x...530
Checking basic setting of fork...530
Adjusting the compression damping of the fork...530
Adjusting the rebound damping of the fork...531
Adjusting the spring preload of the fork (EXC‑F, EXC‑F SIX DAYS, XCF-W)...532
Bleeding fork legs...533
Cleaning the dust boots of the fork legs...533
Loosening the fork protector...533
Positioning the fork protection...533
Checking steering head bearing play...534
Adjusting play of steering head bearing x (EXC‑F EU, EXC‑F AUS, XCF‑W ZA)...534
Adjusting the play of the steering head bearing x (SX‑F, 250 EXC-F SIX DAYS EU)...535
Removing the fork legs...535
Installing the fork legs x...536
Removing the fork protector x...537
Installing the fork protector x...537
Removing the front fender...537
Installing the front fender...538
Removing headlight mask with headlight (EXC‑F, EXC‑F SIX DAYS, XCF-W)...538
Refitting the headlight mask with the headlight (EXC‑F, EXC‑F SIX DAYS, XCF-W)...538
Removing the start number plate (SX‑F)...539
Installing the start number plate (SX‑F)...539
Handlebar position...539
Adjusting handlebar position x...539
Checking throttle cable route...540
Checking the play in the throttle cable...540
Adjusting the play in the throttle cable x...541
Checking for chain dirt accumulation...541
Cleaning the chain...541
Checking the chain tension...542
Checking chain tension when fitting rear wheel...542
Checking the rear sprocket/engine sprocket for wear...542
Checking chain wear...543
Adjusting chain tension...543
Adjusting chain tension - after checking...544
Adjusting chain tension - fitting rear wheel...545
Adjusting the chain guide x (EXC‑F, EXC‑F SIX DAYS, XCF-W)...545
Adjusting the chain guide x (SX‑F)...546
Checking brake discs...546
Checking free travel of hand brake lever...546
Adjusting basic position of hand brake lever (XCF‑W, SX‑F)...547
Adjusting free travel of hand brake lever (EXC-F, EXC‑F SIX DAYS)...547
Checking the brake fluid level of the front brake...547
Topping up the front brake fluid x...548
Checking the front brake linings...549
Changing the front brake linings x...549
Checking free travel of foot brake lever...551
Adjusting basic position of footbrake lever x...551
Checking rear brake fluid level...551
Adding brake fluid to the rear brake circuit x...552
Checking rear brake linings...552
Changing the rear brake linings x...553
Removing front wheel x...554
Installing the front wheel x...555
Removing the rear wheel x...556
Installing the rear wheel x...556
Tire condition checking...557
Checking tire air pressure...558
Checking spoke tension...558
Removing the battery x (EXC‑F, EXC‑F SIX DAYS, XCF-W)...559
Installing the battery x (EXC‑F, EXC‑F SIX DAYS, XCF-W)...559
Recharging the battery x (EXC‑F, EXC‑F SIX DAYS, XCF-W)...559
Removing a fuse (EXC‑F, EXC‑F SIX DAYS, XCF-W)...560
Replacing the fuse (EXC‑F, EXC‑F SIX DAYS, XCF-W)...560
Adjusting the beam width of the headlight (EXC‑F, EXC‑F SIX DAYS, XCF-W)...561
Checking the headlight adjustment (EXC‑F, EXC‑F SIX DAYS, XCF-W)...561
Removing the seat...561
Mounting the seat...562
Dismounting the fuel tank x...562
Installing the fuel tank x...563
Cooling system...563
Checking the anti-freeze and coolant level...564
Checking the coolant level...564
Draining the coolant x...565
Refilling coolant x...565
Glass fiber yarn filling of main silencer...566
Removing main silencer...566
Installing the main silencer...566
Removing the air filter box lid...566
Installing the air filter box lid...566
Removing the air filter x...567
Installing the air filter x...567
Cleaning air filter x...567
Adjusting basic position of clutch lever...568
Checking the fluid level of hydraulic clutch...568
Changing the hydraulic clutch fluid x...568
Checking the basic position of the shift lever...569
Adjusting the basic position of the shift lever x...569
Carburetor - idle...570
Carburetor - adjusting idle x...570
Emptying the carburetor float chamber x...571
Checking the engine oil level...572
Changing the engine oil and oil filter, cleaning the oil screen x...572
Draining the engine oil x...572
Cleaning the oil screens x...573
Removing the oil filter x...574
Installing the oil filter x...574
Filling up with engine oil x...575
Adding engine oil...575
TROUBLESHOOTING...576
CLEANING...578
Cleaning the motorcycle...578
STORAGE...579
Storage...579
Putting into operation after storage...579
TECHNICAL DATA - ENGINE...580
Capacity - engine oil...581
Capacity - coolant...581
TECHNICAL DATA - ENGINE TIGHTENING TORQUES...582
TECHNICAL DATA - CARBURETOR...584
EXC-F, EXC‑F SIX DAYS...584
XCF-W...584
SX‑F...584
TECHNICAL DATA - CHASSIS...585
Lighting equipment...585
Tires...586
Capacity - fuel...586
TECHNICAL DATA - FORK...587
EXC‑F, EXC‑F SIX DAYS, XCF-W...587
SX‑F EU...587
SX‑F USA...588
TECHNICAL DATA - SHOCK ABSORBER...589
EXC‑F, EXC‑F SIX DAYS, XCF-W...589
SX‑F...589
TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS...590
WIRING DIAGRAM...591
Wiring diagram (EXC-F EU, EXC‑F SIX DAYS)...591
Wiring diagram (EXC‑F AUS)...595
Wiring diagram (XCF-W)...597
Wiring diagram (SX‑F)...599
SUBSTANCES...601
AUXILIARY SUBSTANCES...602
STANDARDS...604
INDEX...605
A...605
B...605
C...605
E...605
F...605
H...606
K...606
L...606
M...606
O...606
P...606
R...606
S...606
T...607
U...607
V...607
W...607
Gabel_auswahl_250-F 2008...609
RA250 F 2010-E...610
HOME...0
NOTES AND PREFACE...610
Title page and file spine...610
Important Information...616
Updating Instructions...616
Explanation update...618
Introduction...620
Reply fax for repair manuals...622
TABLE OF CONTENTS...614
GENERAL INFORMATION...624
BLEEDING THE COOLING SYSTEM...626
CHANGING THE OIL FILTER...626
OIL CIRCUIT...627
BLEEDING OF THE HYDRAULIC CLUTCH...628
ADJUSTING THE THROTTLE CABLES...628
SPECIAL TOOLS ENGINE...629
REMOVING AND REFITTING ENGINE...632
DISMOUNTING THE ENGINE...634
MOUNTING THE ENGINE...638
DISASSEMBLING THE ENGINE...642
PREPARATORY WORK...644
MOVING THE ENGINE INTO THE TDC POSITION...645
REMOVING THE CAMSHAFTS...646
REMOVING THE CYLINDER HEAD AND PISTON...647
REMOVING THE CLUTCH COVER...649
DISMANTLING THE CLUTCH...650
REMOVING THE CHAIN DRIVE AND PRIMARY GEAR...651
DISMANTLING THE SHIFT MECHANISM...652
REMOVING THE OIL PUMPS...653
SEPARATING THE CASING HALVES, REMOVING THE CRANKSHAFT AND TRANSMISSION SHAFTS...654
SERVICING INDIVIDUAL COMPONENTS...656
LEFT CASING HALF...658
RIGHT CASING HALF...659
BYPASS VALVE...660
CLUTCH COVER...660
CRANKSHAFT...661
MEASURING THE OUTSIDE DIMENSION OF THE CRANKSHAFT WEBS...662
CRANKSHAFT BEARINGS...662
AXIAL CLEARANCE OF THE CRANKSHAFT...662
CYLINDER...663
MEASURING THE PISTON AND CYLINDER, MOUNTING CLEARANCE...663
PISTON...664
PISTON RING END GAP...664
CHECKING THE OIL PUMPS FOR WEAR...664
LUBRICATING SYSTEM...665
CAMSHAFT BEARING...666
CAMSHAFTS...667
AUTOMATIC DECOMPRESSION...667
CAMSHAFT BEARING BRIDGES...668
TIMING CHAIN TENSIONER...669
TIMING TRAIN...670
CYLINDER HEAD...671
CLUTCH...673
KICKSTARTER...674
PRE-MOUNTING THE KICKSTARTER SHAFT...674
SHIFT MECHANISM...676
PRE-MOUNTING THE SHIFT SHAFT...676
GENERAL INFORMATION ON SERVICING THE TRANSMISSION...677
ASSEMBLING THE MAIN SHAFT...677
ASSEMBLING THE COUNTERSHAFT...678
ASSEMBLING THE ENGINE...680
INSTALLING THE TRANSMISSION SHAFTS AND CRANKSHAFT, ASSEMBLING THE CASING HALVES...682
MOUNTING THE OIL PUMPS...684
MOUNTING THE SHIFT MECHANISM...686
MOUNTING THE PRIMARY PINION AND THE CHAIN DRIVE...687
MOUNTING THE CLUTCH...688
MOUNTING THE CLUTCH COVER...689
MOUNTING THE PISTON AND CYLINDER HEAD...690
MOUNTING THE CAMSHAFTS...693
MOUNTING THE CHAIN TENSIONER...694
CHECKING THE VALVE CLEARANCE...694
ASSEMBLING THE ENGINE...695
ELECTRICAL...696
CDI UNIT...698
CHECKING THE IGNITION COIL...698
TROUBLESHOOTING IN THE IGNITION SYSTEM...698
IGNITION SYSTEM...699
CHECKING THE STATOR AND PULSE GENERATOR...699
REPLACING THE STATOR...699
MAIN FUSE...699
CHECKING THE STARTER...700
CHECKING THE START RELAY...700
DISMOUNTING AND MOUNTING THE BATTERY...700
CHARGING THE BATTERY...700
CHECKING THE CHARGING VOLTAGE...701
CHECKING FOR LOSS OF CURRENT...701
ENGINE CHARACTERISTIC (250 EXC-F EU)...701
MEASURING WITH THE PEAK VOLTAGE ADAPTER...696
STATIC IGNITION VALUES...702
STATIC GENERATOR VALUES...703
THROTTLE VALVE SENSOR...696
ADJUSTING...715
CHECKING...716
FUEL SYSTEM...704
DISMOUNTING AND INSTALLING THE CARBURETOR...707
DISASSEMBLING THE CARBURETOR...708
CHOKE KNOB AND HOT START SLIDE...711
CHECKING THE ACCELERATOR PUMP...711
CHECKING THE JET NEEDLE...711
CHECKING THE FLOAT NEEDLE VALVE...711
CHECKING THE THROTTLE VALVE...711
ASSEMBLING THE CARBURETOR...712
ADJUSTING THE POSITION OF THE THROTTLE VALVE SENSOR...715
CHECKING THE THROTTLE VALVE SENSOR...716
DISMOUNTING AND INSTALLING THE THROTTLE VALVE SENSOR...716
CARBURETOR ADJUSTING IDLING...717
CHECKING/ADJUSTING THE FLOAT HEIGHT...718
TROUBLE SHOOTING...720
TECHNICAL SPECIFICATIONS...724
ENGINE 250 SX-F MODEL 2005-07...726
ENGINE 250 SXS-F MODEL 2006-07...726
CHASSIS 250 SX-F MODEL 2005-06...727
CHASSIS 250 SXS-F MODEL 2006...727
CHASSIS 250 SX-F/SXS-F MODEL 2007...728
ENGINE 250 XC-F, XCF-W, EXC-F MODEL 2007...729
CHASSIS 250 XC-F, XCF-W, EXC-F MODEL 2007...730
ENGINE 250 SX-F, XC-F, XCF-W, EXC-F MODEL 2008...731
CHASSIS 250 SX-F, XC-F, XCF-W, EXC-F MODEL 2008...732
ENGINE 250 SX-F, XC-F, XCF-W, EXC-F MODEL 2009...734
CHASSIS 250 SX-F, XC-F, XCF-W, EXC-F MODEL 2009...736
ENGINE 250 SX-F, XCF-W, EXC-F MODEL 2010...742
CHASSIS 250 SX-F, XCF-W, EXC-F MODEL 2010...744
MOUNTING CLEARANCES, WEAR LIMITS...749
TIGHTENING TORQUES...724
ENGINE...750
CHASSIS...751
PERIODIC MAINTENANCE SCHEDULE...752
MODEL 2005...753
MODEL 2006...755
MODEL 2007...757
MODEL 2008...752
250 SX-F, XC-F...759
250 XCF-W, EXC-F...761
MODEL 2009...752
250 SX-F, XC-F...763
250 XCF-W, EXC-F...765
MODEL 2010...752
250 SX-F...767
250 XCF-W, EXC-F...769
WIRING DIAGRAMS...772
MODEL 2005...772
250 SX-F...774
250 EXC-F USA...775
MODEL 2006...772
250 SX-F...774
250 EXC-F USA...775
250 EXC-F EU...776
MODEL 2007...772
250 SX-F...777
250 EXC-F EU...776
250 XC-F, XCF-W...778
MODEL 2008...772
250 SX-F...779
250 XC-F, XCF-W...780
250 EXC-F...781
CABLE COLORS...782
MODEL 2009...772
250 SX-F...783
250 XCF-W, XC-F USA...785
250 EXC-F AUS...787
250 EXC-F EU, EXC-F SIX DAYS...789
MODEL 2010...772
250 SX-F...791
250 XCF-W...793
250 EXC-F AUS...795
250 EXC-F EU, EXC-F SIX DAYS...797
Start...799
bed_auswahl_250-F-e...800
pds_Auswahl E...801
KTM 250, 300 SX, SXS, MXC, EXC, EXC SIX DAYS, XC, XC-W Repair Manual 2004-2006...802
HOME...0
NOTES AND PREFACE...802
Title page and file spine...802
Important information...808
Updating instructions...808
Explanation updating...810
Introduction...812
Reply fax for repair manuals...814
TABLE OF CONTENTS...806
GENERAL INFORMATION...816
SPECIAL TOOLS - ENGINE...818
CHECKING THE SETTING OF THE TVC SYSTEM...819
ENGINE CHARACTERISTIC...819
BLEEDING THE HYDRAULIC CLUTCH (UP TO MODEL 2005)...820
BLEEDING THE HYDRAULIC CLUTCH (AS OF MODEL 2006)...821
CHANGING THE FRONT BRAKE FLUID...822
CHANGING THE REAR BRAKE FLUID...823
CHECKING BRAKE PADS AND BRAKE DISCS...823
REMOVING AND REFITTING ENGINE...824
REMOVING THE ENGINE...826
REFITTING THE ENGINE...828
DISASSEMBLING THE ENGINE...832
PREPARATION...834
DRAINING THE GEAR OIL...834
DISMOUNTING THE SPROCKET AND SHIFT LEVER...834
DISMOUNTING THE CYLINDER HEAD, CYLINDER AND PISTON...834
DISMOUNTING THE CLUTCH COVER...835
DISMOUNTING THE PRESSURE CAP AND THE CLUTCH DISCS...836
DISMOUNTING THE PRIMARY DRIVE...836
DISMOUNTING THE KICKSTARTER SHAFT...837
DISMOUNTING THE SHIFT LOCK...837
DISMOUNTING THE IGNITION COVER...837
DISMOUNTING THE IGNITION...838
DISMOUNTING THE REED VALVE HOUSING...839
PARTING THE ENGINE HOUSING HALVES...839
DISMOUNTING THE GEARSHIFT MECHANISM AND TRANSMISSION...839
DISMOUNTING THE CRANKSHAFT...840
SERVICING INDIVIDUAL COMPONENTS...842
SERVICING THE RIGHT ENGINE HOUSING HALF...844
SERVICING THE LEFT ENGINE HOUSING HALF...845
CRANKSHAFT...846
CRANKSHAFT WEBS - MEASURE OUTER DIMENSION...846
CHECK THE PISTON...846
PISTON RING END GAP...846
MEASURING PISTONS AND CYLINDERS - ESTABLISHING THE PISTON MOUNTING CLEARANCE...847
RECOATED CYLINDER...847
NIKASIL COATING OF CYLINDER...847
CYLINDER EXHAUST CONTROL SYSTEM...848
CYLINDER PREASSEMBLY...848
EXHAUST CONTROL, CLUTCH COVER...850
PREASSEMBLY OF CLUTCH COVER...850
REED VALVE HOUSING...851
CLUTCH...852
REPLACE OUTER CLUTCH HUB...853
SHIFT MECHANISM...854
PREASSEMBLY THE SHIFT SHAFT...854
ASSEMBLY MAINSHAFT...855
ASSEMBLY COUNTERSHAFT...856
CHECKING THE KICKSTARTER FOR WEAR...857
ASSEMBLING THE KICKSTARTER SHAFT...857
ASSEMBLING THE ENGINE...858
CRANKSHAFT...860
TRANSMISSION...860
ASSEMBLING THE ENGINE HOUSING...861
MOUNTING THE SHIFT MECHANISM...862
MOUNTING THE KICKSTARTER SHAFT...862
MOUNTING THE PRIMARY DRIVE AND CLUTCH...863
MOUNTING THE CLUTCH DISCS AND PRESSURE CAP...864
MOUNTING THE CLUTCH COVER...864
MOUNTING THE PISTON AND CYLINDER...865
ADJUSTING DIMENSION “X“...865
ADJUSTING THE CONTROL FLAP (DIMENSION “Z“)...866
MOUNTING THE STEERING COVERS...867
MOUNTING THE CYLINDER HEAD...867
MOUNTING THE REED VALVE HOUSING...867
MOUNTING THE ENGINE SPROCKET...868
MOUNTING THE IGNITION...868
MOUNTING THE IGNITION COVER...869
MOUNTING THE STARTING LEVER AND SHIFT LEVER...869
FILLING UP THE TRANSMISSION OIL...869
CHECK THE TRANSMISSION OIL LEVEL...869
ELECTRICAL...870
IGNITION COIL...872
CDI UNIT...872
CHECKING THE VOLTAGE REGULATOR...872
CHECKING THE CAPACITOR...873
SPARK PLUG...873
IGNITION...874
CHECK THE STATOR AND PULSE GENERATOR (PICK UP)...874
MEASUREMENTS WITH PEAK VOLTAGE ADAPTER...0
MODEL 2004...0
STATIC IGNITION VALUES 250 SX, 250/300 MXC/EXC...875
STATIC GENERATOR VALUES 250/300 MXC/EXC...877
STATIC IGNITION AND GENERATOR VALUES 250 EXC USA...879
MODEL 2005...0
STATIC IGNITION VALUES 250 SX, 250/300 MXC/EXC...881
STATIC GENERATOR VALUES 250/300 MXC/EXC...883
STATIC IGNITION AND GENERATOR VALUES 250 EXC USA...885
MODEL 2006...0
STATIC IGNITION VALUES 250 SX/SXS, 250/300 EXC/EXC SIX DAYS, 300 XC/XC-W...881
STATIC GENERATOR VALUES 250/300 EXC/EXC SIX DAYS, 300 XC-W...883
STATIC IGNITION AND GENERATOR VALUES 250 XC/XC-W...885
FUEL SYSTEM...888
OPERATING RANGES OF THE CARBURETOR...890
CARBURETOR ADJUSTMENT...891
DISMOUNTING AND INSTALLING THE CARBURETOR...893
DISASSEMBLING THE CARBURETOR...894
CHECKING THE JET NEEDLE AND THROTTLE SLIDE...895
CHECKING THE STARTING PISTON...895
CHECKING THE FLOAT NEEDLE VALVE...895
CHECKING THE CARBURETOR JETS AND GASKETS...895
ASSEMBLING THE CARBURETOR...896
DRAINING THE CARBURETOR FLOAT CHAMBER...897
CHECKING THE FLOAT LEVEL...897
TROUBLE SHOOTING...898
TROUBLE SHOOTING 250 / 300...900
TECHNICAL SPECIFICATIONS...902
MODEL 2004...0
ENGINE...904
CHASSIS...905
MODEL 2005...0
ENGINE...906
CHASSIS...907
MODEL 2006...0
ENGINE 250...908
ENGINE 300...909
CHASSIS SX / SXS / EXC / EXC SIX DAYS...910
CHASSIS XC / XC-W...911
TIGHTENING TORQUES - ENGINE...912
TOLERANCES AND FITTING CLEARANCES / GASKET THICKNESSES...912
TIGHTENING TORQUES - CHASSIS...913
CARBURATOR SPECIFICATION...0
MODEL 2004...914
MODEL 2005...916
MODEL 2006...918
PERIODIC MAINTENANCE SCHEDULE...922
MODEL 2004 / 2005...924
MODEL 2006...927
WIRING DIAGRAM...930
MODEL 2004...0
250/300 EXC...932
250/300 EXC-USA...938
250 SX...939
TERMS/TRANSLATIONS, CABLE COLORS...958
LIST OF SWITCHES...960
MODEL 2005...0
250/300 EXC/EXC SIX DAYS...940
250 EXC-USA...946
300 EXC-USA...947
250 SX...948
TERMS/TRANSLATIONS, CABLE COLORS...958
LIST OF SWITCHES...960
MODEL 2006...0
250/300 EXC...949
250/300 EXC SIX DAYS...940
250 XC-W...955
300 XC-W...956
250 SX/SXS/XC...957
300 XC...957
TERMS/TRANSLATIONS, CABLE COLORS...958
LIST OF SWITCHES...960
KTM 250-300-380 SX, MXC, EXC Repair Manual - Engine...961
HOME...0
NOTES AND PREFACE...961
Titel page and file spine...961
Important information...967
Updating instructions...967
Explanation updating...969
Introduction ...971
Replay fax for repair manuals...973
TABLE OF CONTENTS...965
GENERAL INFORMATION...974
OPERATING RANGES OF THE CARBURETOR...976
CARBURETOR ADJUSTMENT...977
CHECKING OF THE SETTING OF THE TVC SYSTEM...978
BLEEDING OF THE HYDRAULIC CLUTCH...978
SPECIAL TOOLS - ENGINE...979
CLEANING...980
STORAGE...980
REMOVING AND REFITTING ENGINE...982
REMOVING THE ENGINE...984
REFITTING THE ENGINE...986
DISASSEMBLING THE ENGINE...988
DRAINING GEAR OIL...990
DISMOUNTING OF SPROCKET AND SHIFT LEVER...990
DISMOUNTING OF CYLINDER HEAD, CYLINDER AND PISTON...990
DISMOUNTING OF CLUTCH COVER...991
DISMOUNTING OF PRESSURE CAP AND CLUTCH DISCS...992
DISMOUNTING OF THE PRIMARY DRIVE...992
DISMOUNTING OF KICKSTARTER...993
DISMOUNTING OF THE SHIFT LOCK...993
DISMOUNTING OF IGNITION COVER...993
DISMOUNTING OF THE IGNITION (KOKUSAN)...994
DISMOUNTING OF THE IGNITION (SEM)...994
DISMOUNTING OF INTAKE FLANGE AND REED VALVE HOUSING...995
PARTING OF ENGINE HOUSING HALVES...995
DISMOUNTING OF GEARSHIFT MECHANISM AND TRANSMISSION...995
DISMOUNTING OF THE CRANKSHAFT...996
SERVICING ON INDIVIDUAL COMPONENTS...997
WORKING ON THE RIGHT-HAND HOUSING HALF...999
WORKING ON THE LEFT-HAND HOUSING HALF...1000
CRANKSHAFT...1001
CRANKSHAFT WEBS – MEASURE OUTER DIMENSION...1001
PISTON...1001
PISTON RING END GAP...1001
CHECKING CYLINDER FOR WEAR...1002
RECOATED CYLINDER...1002
NIKASIL COATING OF CYLINDER...1002
CYLINDER EXHAUST CONTROL SYSTEM...1003
CYLINDER PREASSEMBLY...1003
EXHAUST CONTROL, CLUTCH COVER...1005
PREASSEMBLY OF CLUTCH COVER...1005
REED VALVE HOUSING, INTAKE FLANGE...1006
CLUTCH...1007
REPLACE OUTER CLUTCH HUB...1008
SHIFT MECHANISM...1009
PREASSEMBLY OF SHIFT SHAFT...1009
IGNITION (KOKUSAN)...1010
SPARK PLUG...1010
CHECK STATOR AND PULSE GENERATOR (KOKUSAN)...1010
IGNITION (SEM)...1011
CHECK STATOR (SEM)...1011
TRANSMISSION...1012
ASSEMBLY MAINSHAFT...1012
ASSEMBLY COUNTERSHAFT...1013
KICKSTARTER...1014
ASSEMBLE OF KICKSTARTER SHAFT...1014
ASSEMBLING THE ENGINE...1015
CRANKSHAFT...1017
TRANSMISSION...1017
ASSEMBLING THE ENGINE HOUSING...1018
MOUNTING SHIFT MECHANISM...1019
MOUNTING KICKSTARTER...1019
MOUNT PRIMARY DRIVE AND CLUTCH...1020
MOUNTING CLUTCH DISCS AND PRESSURE CAP...1021
MOUNTING CLUTCH COVER...1021
MOUNTING PISTON AND CYLINDER...1022
ADJUSTING DIMENSION „X“...1022
ADJUSTING CONTROL FLAP (DIMENSION „Z“)...1023
MOUNTING STEERING COVERS...1024
MOUNTING CYLINDER HEAD...1024
MOUNTING REED VALVE HOUSING AND INTAKE FLANGE...1024
MOUNTING ENGINE SPROCKET...1025
MOUNTING THE IGNITION (KOKUSAN)...1025
MOUNTING THE IGNITION (SEM)...1026
ADJUSTING IGNITION POINT (SEM)...1026
MOUNTING IGNITION COVER...1026
MOUNTING STARTING LEVER AND SHIFT LEVER...1026
ELECTRICAL...1027
CHECKING THE VOLTAGE REGULATOR-RECTIFIER (SHINDENGEN)...1029
CHECKING THE VOLTAGE REGULATOR (KOKUSAN)...1029
CHECKING THE VOLTAGE REGULATOR (TYMPANIUM)...1029
CHECKING THE CAPACITOR...1030
IGNITION COIL (SEM)...1030
IGNITION COIL (KOKUSAN)...1030
CDI UNIT...1030
CHECKING THE VOLTAGE REGULATOR (MOD. 2000)...1031
CHECKING THE CAPACITOR (MOD. 2000)...1031
STATIC IGNITION VALUES 250 - 380 SX, EXC...1032
STATIC GENERATOR VALUES 250 - 380 EXC...1034
STATIC IGNITION AND GENERATOR VALUES 250 MXC, EXC (USA)...1036
TROUBLE SHOOTING...1039
TROUBLE SHOOTING 250 - 380...1041
TECHNICAL SPECIFICATIONS...1043
MODEL 1999 ENGINE 250 - 380 USA...1045
MODEL 1999 - ENGINE 250 - 380...1047
MODEL 1999 - CHASSIS 250 - 380...1049
MODEL 1999 - CARBURETOR SETTINGS...1050
MODEL 2000 ENGINE 250 - 380 USA...1053
MODEL 2000 - ENGINE 250 - 380...1055
MODEL 2000 - CHASSIS 250 - 380...1057
MODEL 2000 - CARBURETOR SETTINGS...1058
MODEL 2001 ENGINE 250 - 380 USA...1063
MODEL 2001 - ENGINE 250 - 380...1065
MODEL 2001 - CHASSIS 250 - 380...1067
MODEL 2001 - CARBURETOR SETTINGS...1068
MODEL 2002 ENGINE 250 - 380 USA...1072
MODEL 2002 - ENGINE 250 - 380...1074
MODEL 2002 - CHASSIS 250 - 380...1076
MODEL 2002 - CARBURETOR SETTINGS...1077
MODEL 2003 - ENGINE 250 - 300...1081
MODEL 2003 - CHASSIS 250 - 300...1083
MODEL 2003 CARBURETOR SETTINGS...1085
PERIODIC MAINTENANCE SCHEDULE...1087
MODEL 1999...1089
MODEL 2000...1091
MODEL 2001/2002...1092
MODEL 2003...1094
WIRING DIAGRAMS...1097
MODEL 1999...1099
MODEL 2000...1103
MODEL 2001 / 2002...1107
MODEL 2003...1111
KTM 250-400-450-520-525-540-610 Series Repair Manual 2000-2006...1114
Dual Compression Control Manual...1115
HOME...0
TITLE PAGE...1115
Front Fork Assembly - 4357_4860 MX Multi Adjuster...1138
HOME...0
TITLE PAGE...1138
Front Forks Assembly...1188
HOME...0
TITLE PAGE...1188
Owners Manual...1203
HOME...0
TITEL PAGE...1203
Service Manual...1273
HOME...0
NOTES AND PREFACE...1273
Title page and file spine...1273
Important information...1279
Updating instructions...1279
Explanation updating...1281
Introduction...1283
Reply fax for repair manuals...1285
TABLE OF CONTENTS...1277
GENERAL INFORMATION...1287
OIL CIRCUIT...1289
ENGINE OIL...1290
CHECKING THE ENGINE OIL LEVEL...1290
CHANGING THE ENGINE OIL...1291
CHANGING THE OIL FILTERS...1292
CHECKING THE OIL LEVEL OF THE HYDRAULIC CLUTCH...1293
BLEEDING THE HYDRAULIC CLUTCH...1293
CHANGING THE FRONT BRAKE FLUID...1294
CHANGING THE REAR BRAKE FLUID...1295
CHECKING BRAKE PADS AND BRAKE DISCS...1295
SPECIAL TOOLS - RACING ENGINE...1296
REMOVING AND REFITTING THE ENGINE...1299
REMOVING THE ENGINE...1301
REFITTING THE ENGINE...1304
BLEEDING THE COOLING SYSTEM...1306
CHECKING THE ADJUSTMENT OF THE HAND DECOMPRESSION RELEASE CABLE...1306
ADJUSTING THE THROTTLE CABLES...1306
DISASSEMBLING THE ENGINE...1307
DRAINING THE ENGINE OIL...1309
DISMOUNTING THE OIL FILTER...1309
DISMOUNTING THE CHAIN WHEEL...1309
DISASSEMBLING THE CLUTCH...1310
DISMOUNTING THE IGNITION SYSTEM (400/520 MODELS UNTIL 2002)...1310
DISMOUNTING THE IGNITION SYSTEM AND LOOSENING THE PRIMARY GEAR (250 EXC MODELS FROM 2002, 450/525 MODELS FROM 2003)...1311
PULLING OFF THE FLYWHEEL...1312
REMOVING THE CLUTCH DRIVE AND THE OUTER CLUCH HUB...1312
DISMOUNTING THE OIL PUMP...1313
DISMOUNTING THE UPPER CYLINDER HEAD PORTION...1314
DISMOUNTING CYLINDER HEAD, CYLINDER AND PISTON...1314
DISMOUNTING THE TIMING CHAIN AND THE TIMING GEAR...1316
DISMOUNTING THE E-STARTER DRIVE GEAR AND KICKSTARTER...1317
DISMOUNTING THE PRIMARY GEAR AND FREEWHEEL...1318
DISMOUNTING THE SHIFT MECHANISM AND TRANSMISSION...1319
DISMOUNTING THE BALANCER SHAFT AND CRANKSHAFT...1320
SERVICING INDIVIDUAL COMPONENTS...1321
LEFT CASING HALF...1323
RIGHT CASING HALF...1324
CLUTCH COVER...1326
CRANKSHAFT...1327
CRANKSHAFT WEBS - MEASURE OUTER DIMENSION...1328
DRIVE WHEEL FOR BALANCER SHAFT...1328
MEASURING THE AXIAL CLEARANCE FOR THE CRANKSHAFT AND TRANSMISSION SHAFTS...1328
COMPENSATING THE AXIAL CLEARANCE FOR THE CRANKSHAFT AND TRANSMISSION SHAFTS...1329
CYLINDER - NICASIL COATING...1329
MEASURING PISTON AND CYLINDER, PISTON FITTING CLEARANCE...1329
CHECKING THE PISTON...1330
MEASURING THE PISTON RING END GAP...1330
CHECKING THE OIL PUMPS FOR WEAR...1330
LUBRICATION SYSTEM...1331
UPPER PORTION OF CYLINDER HEAD...1332
CYLINDER HEAD...1333
REPLACING THE VALVE GUIDES (CYLINDER HEAD DISASSEMBLED)...1334
CAMSHAFT...1335
PREASSEMBLING THE CAMSHAFT...1336
TIMING CHAIN TENSIONER...1337
TIMING TRAIN...1337
CHECKING THE CLUTCH FOR WEAR - UP TO THE 2002 MODEL...1338
CHECKING THE CLUTCH FOR WEAR - FROM THE 2003 MODEL...1339
CHECKING THE KICKSTARTER FOR WEAR...1340
PREASSEMBLING THE KICKSTARTER SHAFT...1340
SHIFT MECHANISM...1342
PREASSEMBLING THE SHIFT SHAFT...1342
ASSEMBLING THE MAIN SHAFT (4-SPEED)...1343
ASSEMBLING THE MAIN SHAFT (6-SPEED)...1344
ASSEMBLING THE COUNTERSHAFT...1345
E-STARTER DRIVE GEAR...1346
CHECKING THE FREE WHEEL...1347
REPLACING THE FREE WHEEL HUB...1347
ASSEMBLING THE ENGINE...1349
MOUNTING THE CRANKSHAFT AND BALANCER SHAFT...1351
MOUNTING THE SHIFT MECHANISM AND TRANSMISSION...1351
ASSEMBLING THE ENGINE CASING...1353
MOUNTING THE PRIMARY GEAR AND FREE WHEEL...1353
MOUNTING THE OIL PUMPS...1354
MOUNTING THE SHIFT ARRESTER...1355
MOUNTING THE E-STARTER DRIVE GEAR AND KICKSTARTER...1355
MOUNTING THE OUTER CLUTCH HUB AND DRIVER UP TO THE 2002 MODEL...1356
MOUNTING THE OUTER CLUTCH HUB AND DRIVER FROM THE 2003 MODEL ONWARDS...1357
MOUNTING THE PRIMARY GEAR NUT (250 EXC AND ALL MOD. FROM 2003)...1357
MOUNTING THE TIMING GEAR...1358
MOUNTING THE PISTON AND CYLINDER...1359
MOUNTING THE CYLINDER HEAD...1359
MOUNTING THE CYLINDER HEAD TOP PORTION...1361
MOUNTING THE TIMING CHAIN TENSIONER...1362
ADJUSTING THE VALVE CLEARANCE...1362
MOUNTING THE FLYWHEEL...1363
MOUNTING THE PULSE GENERATOR AND THE IGNITION COVER...1363
MOUNTING THE CLUTCH...1364
MOUNTING THE OIL LINE...1365
MOUNTING THE ELECTRIC STARTER...1365
MOUNTING THE OIL FILTERS...1366
HOW TO FILL IN ENGINE OIL...1366
ELECTRICAL...1367
LEAKAGE INSPECTION...1369
REMOVING THE BATTERY...1369
CHARGING THE BATTERY...1369
FILLING THE BATTERY...1370
CHECKING THE CAPACITOR...1370
CHECKING THE VOLTAGE REGULATOR-RECTIFIER...1371
CHECKING THE CHARGING VOLTAGE...1371
CDI UNIT...1372
CHECKING THE IGNITION COIL...1372
TROUBLESHOOTING IN THE IGNITION SYSTEM...1372
IGNITION...1373
CHECK STATOR AND PULSE GENERATOR...1373
REPLACING THE STATOR...1373
MAIN FUSE...1374
CHECKING THE ELECTRIC STARTER MOTOR...1374
CHECKING THE STARTER RELAY...1374
MEASUREMENTS WITH PEAK VOLTAGE ADAPTER...0
STATIC IGNITION VALUES 4K-3A, 4K-3B...1375
STATIC GENERATOR VALUES 4K-3B...1377
DYNAMIC GENERATOR VALUES 4K-3B...1378
THROTTLE VALVE SENSOR...0
ADJUSTMENT...1397
CHECK...1398
FUEL SYSTEM...1379
DISMOUNTING AND INSTALLING THE CARBURETOR...1383
DISASSEMBLING THE CARBURETOR (KEIHIN FCR 35/39)...1384
DISASSEMBLING THE CARBURETOR (KEIHIN FCR-MX 37/39/41)...1387
CHECKING THE CHOKE SLIDE AND HOT START KNOB...1390
CHECKING THE ACCELERATOR PUMP...1390
CHECKING THE JET NEEDLE...1390
CHECKING THE FLOAT NEEDLE VALVE...1390
CHECKING THE THROTTLE VALVE...1390
ASSEMBLING THE CARBURETOR (KEIHIN FCR 35/39)...1391
ASSEMBLING THE CARBURETOR (KEIHIN FCR-MX 37/39/41)...1394
ADJUSTING THE POSITION OF THE THROTTLE VALVE SENSOR...1397
CHECKING THE THROTTLE VALVE SENSOR...1398
DISMOUNTING AND INSTALLING THE THROTTLE VALVE SENSOR...1398
ADJUSTING IDLING (KEIHIN FCR 35/39)...1399
CHECKING THE FLOAT HEIGHT...1399
ADJUSTING IDLING (KEIHIN FCR-MX 37/39/41)...1400
CHECKING THE FLOAT HEIGHT...1400
TROUBLE SHOOTING...1401
TROUBLE SHOOTING 250 - 610 RACING...1403
TECHNICAL SPECIFICATIONS...1405
MODEL 2000...1405
ENGINE...1409
BASIC CARBURETOR SETTING...1409
CHASSIS...1410
STANDARD ADJUSTMENT FORK / SHOCK ABSORBER...1410
MODEL 2001...1405
ENGINE...1411
BASIC CARBURETOR SETTING...1411
CHASSIS...1412
STANDARD ADJUSTMENT FORK / SHOCK ABSORBER...1412
MODEL 2002...1405
ENGINE...1413
BASIC CARBURETOR SETTING...1414
CHASSIS...1415
STANDARD ADJUSTMENT FORK / SHOCK ABSORBER...1415
MODEL 2003...1405
ENGINE...1416
BASIC CARBURETOR SETTING...1417
CHASSIS...1418
STANDARD ADJUSTMENT FORK / SHOCK ABSORBER...1418
MODEL 2004...1405
ENGINE 250/450/525 SX,MXC,EXC...1419
BASIC CARBURETOR SETTING 250/450/525 SX,MXC,EXC...1420
ENGINE 400 EXC, 450/525 SMR, 450/540 SXS...1421
BASIC CARBURETOR SETTING 400 EXC, 450/525 SMR, 450/540 SXS...1422
CHASSIS 250/450/525 SX,MXC,EXC...1423
STANDARD ADJUSTMENT FORK / SHOCK ABSORBER 250/450/525 SX,MXC,EXC...1423
CHASSIS 400 EXC, 450/525 SMR, 450/540 SXS...1424
STANDARD ADJUSTMENT FORK / SHOCK ABSORBER 400 EXC, 450/525 SMR, 450/540 SXS...1425
MODEL 2005...1407
ENGINE 250/400/450/525 SX,MXC,EXC...1426
BASIC CARBURETOR SETTING 250/450/525 SX,MXC,EXC...1427
ENGINE 400 EXC, 450/525 SMR, 450/540 SXS...1428
BASIC CARBURETOR SETTING 450/525 SMR, 540 SXS, 610 CRATE...1429
CHASSIS 250/400/450/525 SX,MXC,EXC...1430
STANDARD ADJUSTMENT FORK / SHOCK ABSORBER 250/400/450/525 SX,MXC,EXC...1430
CHASSIS 450/525 SMR, 540 SXS...1431
STANDARD ADJUSTMENT FORK / SHOCK ABSORBER 450/525 SMR, 540 SXS...1431
MODEL 2006...1407
ENGINE SX,XC,EXC RACING...1432
ENGINE SMR,SXS...1433
BASIC CARBURETOR SETTING...1434
CHASSIS SX,XC,EXC RACING...1435
CHASSIS SMR,SXS...1436
STANDARD ADJUSTMENT FORK / SHOCK ABSORBER...1437
MOUNTING CLEARANCES, WEAR LIMITS...1438
TIGHTENING TORQUES - ENGINE...1440
TIGHTENING TORQUES - CHASSIS...1441
PERIODIC MAINTENANCE SCHEDULE...1443
MODEL 2000...1444
MODEL 2001...1446
MODEL 2002...1448
MODEL 2003...1450
MODEL 2004...1454
MODEL 2005...1458
MODEL 2006...1461
WIRING DIAGRAMS...1465
MODEL 2000...0
USA...1467
EU...1468
MODEL 2001...0
EU/AUS...1470
USA...1472
MODEL 2002...0
USA...1473
EU/AUS...1474
MODEL 2003...0
USA...1476
EU/AUS...1478
MODEL 2004...0
EXC USA...1479
EXC EU/AUS...1480
SX...1481
TERMS/TRANSLATIONS, CABLE COLORS...1493
MODEL 2005...0
MXC DESERT RACING, EXC EU/AUS...1482
MXC-G, EXC USA...1483
SX, SXS, SMR...1484
TERMS/TRANSLATIONS, CABLE COLORS...1493
MODEL 2006...0
XC DESERT RACING, EXC EU/AUS...1485
XC-G, EXC USA...1483
SX, SXS, SMR...1484
LIST OF SWITCHES...1492
TERMS/TRANSLATIONS, CABLE COLORS...1493
Shock Absorber Assembly...1495
HOME...0
TITLE PAGE...1495
WP FORK SXS_SMR 4860 MXMA Repair Manual '05-'06...1555
HOME...0
NOTES...1555
Title page...1555
Explanation updating...1559
Introduction...1561
Reply fax for repair manuals...1563
TABLE OF CONTENTS...1557
SPECIAL TOOLS...1565
GENERAL INFORMATION...1573
EXPLODED VIEW SXS 2005...1575
PART LIST SXS 2005...1576
SETTING LIST 125 SXS MODEL 2005...1577
SETTING LIST 250 SXS MODEL 2005...1578
SETTING LIST 450/540 SXS MODEL 2005...1579
EXPLODED VIEW SXS/SMR 2006...1580
PART LIST SXS/SMR 2006...1581
SETTING LIST 125 SXS MODEL 2006...1582
SETTING LIST 250 SXS MODEL 2006...1583
SETTING LIST 450/540 SXS MODEL 2006...1584
SETTING LISTE 450/560 SMR MODEL 2006...1585
ADJUSTMENTS...1586
ADJUSTING THE POSITION OF THE COMPRESSION AND REBOUND DAMPING...1586
EXPLANATION OF THE SPRING PRELOAD...1587
BLEEDER SCREW...1588
RECOMMENDED PERIODICAL MAINTENANCE INTERVALS...1588
DISMOUNTING/MOUNTING THE FORK...1589
DISMOUNTING THE FORK...1591
MOUNTING THE FORK...1592
DISASSEMBLING AND ASSEMBLING THE FORK...1593
DISASSEMBLING THE CARTRIDGE OUT OF THE FRONT FORK LEG...1595
INSPECTION OF THE SPRING...1599
DISASSEMBLING THE INNER-TUBE / OUTER-TUBE...1599
INSPECTION OF THE OUTER-TUBE...1601
INSPECTION OF THE DU-BUSHES, SUPPORT RING AND SEALS...1605
INSPECTION OF THE INNER-TUBE...1608
DISASSEMBLING THE CLOSED CARTRIDGE...1611
RELEASE THE NITROGEN GAS PRESSURE...1612
INSPECTION OF THE PISTON ROD...1617
DISASSEMBLING THE MEMBRANE HOLDER...1619
INSPECTION OF THE CHECK VALVE SPRING...1621
DISASSEMBLING THE SCREW SLEEVE...1623
DISASSEMBLING THE REBOUND ADJUSTMENT ADAPTOR...1626
DISASSEMBLING THE TAP REBOUND...1627
INSPECTION OF THE REBOUND SETTING...1630
DISASSEMBLING THE SCREW-CAP / MEMBRANE CC...1631
ASSEMBLING THE SCREW-CAP/MEMBRANE CC...1637
DISASSEMBLING THE TAP COMPRESSION...1642
INSPECTION OF THE COMPRESSION SETTING...1644
ASSEMBLING THE TAP COMPRESSION...1644
ASSEMBLING THE HOLDER MEMBRANE...1646
ASSEMBLING THE TAP REBOUND...1649
ASSEMBLING THE REBOUND ADJUSTMENT ADAPTOR...1652
ASSEMBLING THE SCREW SLEEVE...1653
ASSEMBLING THE CLOSED CARTRIDGE (MODEL 2005)...1655
ASSEMBLING THE CLOSED CARTRIDGE (STARTING WITH MODEL 2006)...1659
BLEEDING THE CLOSED CARTRIDGE (MODEL 2005)...1662
BLEEDING THE CLOSED CARTRIDGE (STARTING WITH MODEL 2006)...1664
ON PRESSURE WITH NITROGEN...1667
ASSEMBLING THE INNER-TUBE / OUTER-TUBE...1669
ASSEMBLING THE CARTRIDGE IN THE FRONT FORK LEG...1675
FILLING OIL IN THE FRONT FORK LEG...1677
WP SHOCK ABSORBER_5018 DCC_5018 SXS_5018 SMR Repair Manual '05-'06...1678
HOME...0
NOTES AND PREFACE...1678
Title page...1678
Explanation update...1682
Introduction...1684
Reply fax for repair manuals...1686
TABLE OF CONTENTS...1680
SPECIAL TOOLS...1688
GENERAL INFORMATION...1696
EXPLODED VIEW PDS 5018 DCC 2006...1697
EXPLODED VIEW PDS 5018 SXS/SMR 2005/2006...1699
SETTING LIST PDS 125 SXS 2005/2006...1701
SETTING LIST PDS 250 SXS 2005...1702
SETTING LIST PDS 250 SXS/250 SXS-F 2006...1703
SETTING LIST PDS 450/540 SXS 2005...1704
SETTING LIST PDS 450/540 SXS 2006...1705
SETTING LIST PDS 450/560 SMR 2006...1706
ADJUSTMENTS...1696
ADJUSTING THE POSITION OF THE COMPRESSION AND REBOUND DAMPING...1707
ADJUSTING THE SPRING PRELOAD...1707
RECOMMENDED PERIODIC MAINTENANCE INTERVALS...1696
PDS 5018 DCC 2006...1696
PDS 5018 SXS/SMR 2005/2006...1707
DISASSEMBLING AND ASSEMBLING THE SHOCK ABSORBER...1708
DISASSEMBLING THE SHOCK ABSORBER...1710
DISASSEMBLING THE TUBE SIDE...1713
DISASSEMBLING ADAPTOR BUSHES AND HEIM JOINT...1717
DISASSEMBLING THE NITROGEN RESERVOIR...1719
ASSEMBLING THE NITROGEN RESERVOIR...1719
ASSEMBLING THE TUBE SIDE...1720
ASSEMBLING ADAPTOR BUSHES AND HEIM JOINT...1721
MOUNTING THE RESERVOIR...1722
INSPECTION OF THE TUBE...1723
MOUNTING THE PIPE...1723
MOUNTING THE DCC MECHANISM...1724
ASSEMBLING THE SHOCK ABSORBER BODY...1724
FILLING THE SHOCK ABSORBER BODY...1725
DISASSEMBLING THE PISTON ROD (DOES NOT APPLY TO SXS/SMR)...1725
DISASSEMBLING THE PISTON ROD (FOR SXS/SMR ONLY)...1727
INSPECTION OF THE PISTON ROD...1733
ASSEMBLING PISTON ROD SIDE...1734
DISASSEMBLING ADAPTOR DU-BUSH...1738
ASSEMBLING ADAPTOR DU-BUSH...1739
CHECKING THE PARTS...1740
PISTONS...1741
CONTINUING TO ASSEMBLE THE PISTON ROD (DOES NOT APPLY TO SXS/SMR)...1742
CONTINUING TO ASSEMBLE THE PISTON ROD (APPLIES TO SXS/SMR ONLY)...1744
ASSEMBLING THE SHOCK ABSORBER...1745
EVACUATING AND FILLING THE SHOCK ABSORBER...1746
ON PRESSURE WITH NITROGEN...1749
ASSEMBLING THE SPRING...1750
MANUAL FOR VACUUM FILLING DEVICE...1752
INTRODUCTION...1754
SUPPLIED PARTS...1754
TECHNICAL FEATURES...1754
OVERVIEW OF VACUUM FILLING DEVICE...1755
GENERAL HANDLING INFORMATION...1756
BEFORE / DURING TRANSPORTATION...1757
PREPARING VACUUM FILLING DEVICE FOR USE (AFTER TRANSPORTATION)...1758
USING THE FILLING ADAPTERS...1760
GENERAL OPERATION INSTRUCTIONS...1760
FREQUENT CHECKS...1772
MAINTENANCE...1775
SPARE PARTS...1779
FILLING LIST...1779
SHORT OPERATION INSTRUCTION FOR VACUUM FILLING UNIT...1780
KTM 250-525 SX_MXC_EXC Racing Repair Manual - Engine...1781
HOME...0
NOTES AND PREFACE...1781
Title page and file spine...1781
Important information...1787
Updating instruction...1787
Explanation update...1789
Introduction...1791
Reply fax for repair manuals...1793
TABLE OF CONTENTS...1785
SERVICE - INFORMATIONS...1785
GENERAL INFORMATION...1794
OIL CIRCUIT...1796
ENGINE OIL...1797
CHECKING THE ENGINE OIL LEVEL...1797
CHANGING THE ENGINE OIL...1798
CHANGING THE OIL FILTERS...1799
CHECKING THE OIL LEVEL OF THE HYDRAULIC CLUTCH...1800
BLEEDING OF THE HYDRAULIC CLUTCH...1800
SPECIAL TOOLS...1802
CLEANING, STORAGE OF MOTORBIKE...1803
REMOVING AND REFITTING ENGINE...1804
DISMOUNTING THE ENGINE...1806
MOUNTING THE ENGINE...1809
BLEEDING THE COOLING SYSTEM...1809
CHECKING THE ADJUSTMENT OF THE HAND DECOMPRESSION RELEASE CABLE...1809
ADJUSTING THE THROTTLE CALBES...1809
DISASSEMBLING ENGINE...1810
DRAINING THE ENGINE OIL...1812
DISMOUNTING THE OIL FILTER...1812
DISMOUNTING THE CHAIN WHEEL...1812
DISASSEMBLING THE CLUTCH...1813
DISMOUNTING THE IGNITION SYSTEM (400/520 MODELS UNTIL 2002)...1813
DISMOUNTING THE IGNITION SYSTEM AND LOOSENING THE PRIMARY GEAR (250 EXC MODELS FROM 2002, 450/525 MODELS FROM 2003)...1814
REMOVING THE FLYWHEEL...1815
REMOVING THE CLUTCH DRIVE AND THE OUTER CLUCH HUB...1815
DISMOUNTING THE OIL PUMP...1816
DISMOUNTING THE UPPER CYLINDER HEAD PORTION...1817
DISMOUNTING CYLINDER HEAD, CYLINDER AND PISTON...1817
DISMOUNTING THE TIMING CHAIN AND THE TIMING GEAR...1819
DISMOUNTING THE E-STARTER DRIVE GEAR AND KICKSTARTER...1820
DISMOUNTING THE PRIMARY GEAR AND FREEWHEEL...1821
DISMOUNTING THE SHIFT MECHANISM AND TRANSMISSION...1822
DISMOUNTING THE BALANCER SHAFT AND CRANKSHAFT...1823
SERVICING INDIVIDUAL COMPONENTS...1824
LEFT CASING HALF...1826
RIGHT CASING HALF...1827
CLUTCH COVER...1829
CRANKSHAFT...1830
CRANKSHAFT WEBS - MEASURE OUTER DIMENSION...1831
DRIVING GEAR OF BALANCER SHAFT...1831
COMPENSATING THE AXIAL CLEARANCE OF THE CRANKSHAFT...1831
CYLINDER - NICASIL COATING...1832
MEASURING PISTON AND CYLINDER, PISTON FITTING CLEARANCE...1832
PISTON...1833
MEASURING PISTON RING END GAP...1833
CHECKING THE OIL PUMPS FOR WEAR...1833
LUBRICATION SYSTEM...1834
UPPER PORTION OF CYLINDER HEAD...1835
CYLINDER HEAD...1836
CAMSHAFT...1838
PREASSEMBLING THE CAMSHAFT...1839
TIMING CHAIN TENSIONER...1840
TIMING TRAIN...1840
CHECKING THE CLUTCH FOR WEAR...1841
CHECKING THE KICKSTARTER FOR WEAR...1843
PREASSEMBLING THE KICKSTARTER SHAFT...1843
SHIFT MECHANISM...1845
PREASSEMBLING THE SHIFT SHAFT...1845
ASSEMBLING THE MAIN SHAFT (4-SPEED)...1846
ASSEMBLING THE MAIN SHAFT (6-SPEED)...1847
ASSEMBLING THE COUNTERSHAFT...1848
IGNITION ...1849
REPLACING THE STATOR...1849
E-STARTER DRIVE GEAR...1850
CHECKING THE FREE WHEEL...1851
REPLACING THE FREE WHEEL HUB...1851
ASSEMBLING ENGINE...1852
MOUNTING THE CRANKSHAFT AND BALANCER SHAFT...1854
MOUNTING THE SHIFT MECHANSIM AND TRANSMISSION...1854
ASSEMBLING THE ENGINE CASE...1856
MOUNTING THE PRIMARY GEAR AND FREE WHEEL...1856
MOUNTING THE OIL PUMPS...1857
MOUNTING THE SHIFT ARRESTER...1858
MOUNTING THE E-STARTER DRIVE GEAR AND KICKSTARTER...1858
MOUNTING THE OUTER CLUTCH HUB AND THE DRIVER...1859
MOUNTING THE PRIMARY GEAR NUT (250 EXC AND ALL MOD. FROM 2003)...1860
MOUNTING THE TIMING GEAR...1861
MOUNTING THE PISTON AND CYLINDER...1862
MOUNTING THE CYLINDER HEAD...1862
MOUNTING THE CYLINDER HEAD TOP PORTION...1864
MOUNTING THE TIMING CHAIN TENSIONER...1865
ADJUSTING THE VALVE CLEARANCE...1865
MOUNTING THE FLYWHEEL...1866
MOUNTING THE PULSE GENERATOR AND THE IGNITION COVER...1866
MOUNTING THE CLUTCH...1867
MOUNTING THE OIL LINE AND THE ELECTRIC STARTER...1868
MOUNTING THE OIL FILTER...1869
HOW TO FILL IN ENGINE OIL...1869
ELECTRICAL...1870
LEAKAGE INSPECTION...1872
REMOVING THE BATTERY...1872
CHARGING THE BATTERY...1872
FILLING THE BATTERY...1873
CHECKING THE CAPACITOR...1873
CHECKING THE VOLTAGE REGULATOR-RECTIFIER...1874
CHECKING THE CHARGING VOLTAGE...1874
CDI UNIT...1875
CHECKING THE IGNITION COIL...1875
TROUBLESHOOTING IN THE IGNITION SYSTEM...1875
MAIN FUSE...1876
CHECKING THE ELECTRIC STARTER MOTOR...1876
CHECKING THE STARTER RELAY...1876
MEASUREMENTS WITH PEAK VOLTAGE ADAPTER...1877
STATIC IGNITION VALUES 250-525 SX, MXC, EXC RACING...1877
STATIC GENERATOR VALUES 250-525 SX, MXC, EXC RACING...1879
DYNAMIC GENERATOR VALUES 250-525 SX, MXC, EXC RACING...1881
THROTTLE VALVE SENSOR...1900
ADJUSTMENT...1900
CHECK...1901
FUEL SYSTEM...1882
DISMOUNTING AND INSTALLING THE CARBURETOR...1886
DISASSEMBLING THE CARBURETOR (KEIHIN FCR 35/39) ...1887
DISASSEMBLING THE CARBURETOR (KEIHIN FCR-MX 37/39/41)...1890
CHOKE SLIDE AND HOT START KNOB...1893
CHECKING THE ACCELERATOR PUMP...1893
CHECKING THE JET NEEDLE...1893
CHECKING THE FLOAT NEEDLE VALVE...1893
CHECKING THE THROTTLE VALVE...1893
ASSEMBLING THE CARBURETOR (KEIHIN FCR 35/39)...1894
ASSEMBLING THE CARBURETOR (KEIHIN FCR-MX 37/39/41)...1897
ADJUSTING THE POSITION OF THE THROTTLE VALVE SENSOR...1900
CHECKING THE THROTTLE VALVE SENSOR...1901
DISMOUNTING AND INSTALLING THE THROTTLE VALVE SENSOR...1901
CARBURETOR ADJUSTING IDLING (KEIHIN FCR 35/39)...1902
CHECKING/ADJUSTING THE FLOAT HEIGHT...1902
CARBURETOR ADJUSTING IDLING (KEIHIN FCR-MX 37/39/41)...1903
CHECKING/ADJUSTING THE FLOAT HEIGHT...1903
TECHNICAL SPECIFICATIONS...1904
MODEL 2000...1906
TECHNICAL SPECIFICATIONS - ENGINE...1906
BASIC CARBURETOR SETTING...1906
TIGHTENING TORQUES - ENGINE...1907
ASSEMBLY CLEARANCE, WEAR LIMIT...1908
TECHNICAL SPECIFICATIONS - CHASSIS...1909
STANDARD ADJUSTMENT - FORK...1909
STANDARD ADJUSTMENT - SHOCK ABSORBER...1909
TIGHTENING TORQUES - CHASSIS...1909
MODEL 2001...1910
TECHNICAL SPECIFICATIONS - ENGINE...1910
BASIC CARBURETOR SETTING...1910
TECHNICAL SPECIFICATIONS - CHASSIS...1911
STANDARD ADJUSTMENT - FORK...1911
STANDARD ADJUSTMENT - SHOCK ABSORBER...1911
MODEL 2002...1912
TECHNICAL SPECIFICATIONS - ENGINE...1912
BASIC CARBURETOR SETTING...1913
MOUNTING CLEARANCES, WEAR LIMITS FOR MODELS UP TO 2002...1914
TECHNICAL SPECIFICATIONS - CHASSIS...1915
STANDARD ADJUSTMENT - FORK...1915
STANDARD ADJUSTMENT - SHOCK ABSORBER...1915
MODEL 2003...1916
TECHNICAL SPECIFICATIONS - ENGINE...1916
BASIC CARBURETOR SETTING...1917
TIGHTENING TORQUES - ENGINE...1918
MOUNTING CLEARANCES, WEAR LIMITS FOR MODELS FROM 2003...1919
TECHNICAL SPECIFICATIONS - CHASSIS...1920
STANDARD ADJUSTMENT FORK / SHOCK ABSORBER...1920
TIGHTENING TORQUES - CHASSIS...1920
PERIODIC MAINTENANCE SCHEDULE...1922
PERIODIC MAINTENANCE SCHEDULE MODEL 2000...1924
PERIODIC MAINTENANCE SCHEDULE MODEL 2001...1926
PERIODIC MAINTENANCE SCHEDULE MODEL 2002...1928
PERIODIC MAINTENANCE SCHEDULE MODEL 2003...1930
WIRING DIAGRAMS...1934
MODEL 2000...1936
WIRING DIAGRAM USA...1936
WIRING DIAGRAM EU...1937
MODEL 2001...1939
WIRING DIAGRAM EU...1939
WIRING DIAGRAM USA...1941
MODEL 2002...1942
WIRING DIAGRAM USA...1942
WIRING DIAGRAM EU...1943
MODEL 2003...1945
WIRING DIAGRAM USA...1945
WIRING DIAGRAM EU...1947
KTM 250MX ('83-'91), 250MXC ('84-'03), 250GS ('83-'99) Owner’s Repair Manual (EN-DE)...1948
KTM250 MX/MXC/GS_1984...1948
Index...1950
Specifications-frame...1951
Maintenance...1954
Specification-motor...1967
Removing motor...1974
Dismantling motor...1974
Individual components...1981
Reassembly...1991
Ignition / Wiring diagrams...2003
Lubrication / Maintenance...2006
Back cover...2010
KTM 250, 300, 380, 400, 520, 525, 540, 560, 610 Repair Service Manual 1983-2010
